Mobile power generation system including air filtration

ABSTRACT

Mobile power generation system and methods for air filtration include providing a trailer including a rear end, a front end, a bottom end, and a top end, a gas turbine housed inside the trailer, an electrical generator coupled to the gas turbine to generate electricity and housed inside the trailer, and a plurality of air inlets disposed on a side panel disposed below the top end and between the rear end and the front end of the trailer, the plurality of air inlets in fluid communication with the gas turbine and the electrical generator, and the plurality of air inlets configured to receive and filter air comprising at least one of combustion air and ventilation air.

TECHNICAL FIELD

The present specification generally relates to power generation systems,and more specifically to mobile power generation systems for operationsthat may use remotely generated power, such as fracking.

BACKGROUND

The present disclosure relates generally to a mobile power generationsystem, and more particularly to a gas turbine-based mobile powergeneration system that can provide electrical power through a generatorto a plurality of electrically driven motors operating as, for example,fluid pumps in a fracturing operation (also referable to as fracking).Such remotely generated power may be in addition to or an alternative ofpower from the grid.

In a fracturing operation, a fluid and additive slurry including sand isinjected at a wellbore into a rock formation that bears hydrocarbon toallow for fracturing as the sand remains in a created fracture in a flowpath in the wellbore while most of the other injected fluids flow backand are recovered from the wellbore. The created fracture with the sandcreates a permeable membrane for hydrocarbon fluids and gases (i.e.,natural gas) to flow through for recovery and use as, for example, anenergy source.

Electrical power may be generated and used to deliver fracturing fluidthrough fluid pumps to a wellbore at the fracturing operation site.Surface pumping systems including such fluid pumps are utilized toaccommodate the various fluids, which pumping systems may be mobilizedat wellbores on, for example, skids or tractor-trailers. A dedicatedsource of power may be a turbine generator coupled to a source ofnatural gas that drives the turbine generator to produce electricalpower. The electrical power may be sent to one or more of the surfacepumping systems through coupling cables such as leads to couple to andoperate the fluid pumps.

The fracturing operation site often encompasses a large footprint withthe number of wellbores and supporting components. The supportingcomponents take time to be transported to the fracturing operation siteand to be setup for utilization at the fracturing operation site withthe wellbores. A reduction in setup time would assist with increasedefficiency in use of such supporting components at the fracturingoperation site. Accordingly, there exists a need for an alternativemobile power generation system.

BRIEF SUMMARY

In one embodiment, a mobile power generation system may include atrailer including a rear end, a front end, a bottom end, and a top enddefining therebetween an interior space, a gas turbine housed inside thetrailer in the interior space, an electrical generator coupled to thegas turbine to generate electricity and housed inside the trailer in theinterior space, and a plurality of air inlets disposed on a side panelof the trailer. The side panel may be disposed below the top end andbetween the rear end and the front end of the trailer. The plurality ofair inlets may be in fluid communication with the gas turbine and theelectrical generator, and the plurality of air inlets may be configuredto receive and filter air comprising at least one of combustion air andventilation air.

In embodiments, the plurality of air inlets may include at least a pairof ventilation air inlets and a plurality of combustion air inlets. Theplurality of combustion air inlets may include a first pair ofcombustion air inlets and a second pair of combustion air inlets. Eachof the plurality of air inlets may be configured to include an openingsized and shaped to hold an air filter, and each combustion air inletmay include an opening configured to receive a pair of air filters suchthat one air filter is stacked within another air filter. The opening ofeach combustion air inlet may be a 2 foot by 2 foot opening. Theplurality of combustion air inlets may include at least a pair ofcombustion air inlets, and a plurality of baffles may be positionedbetween the pair of combustion air inlets, each baffle configured toassist with absorption of noise energy and having a thickness in a rangeof from about 2 inches to about 8 inches thick.

In embodiments, the gas turbine is configured to receive combustion airfrom the plurality of combustion air inlets and the electrical generatoris configured to receive a portion of ventilation air from the pair ofventilation air inlets. The trailer may further include a plenumcentrally disposed between and in fluid cooperation with the pluralityof combustion air inlets, and the gas turbine may include a ductdownstream of the plenum and disposed between the plenum and the gasturbine, the plenum and the duct configured for receipt of combustionair. The duct may include a bell-mouth inlet duct configured to be aconvergent inlet air duct to direct combustion air into an inlet of thegas turbine. The bell-mouth inlet duct may include an area thatdecreases in size in a downstream direction in which combustion airflows into the gas turbine. The inlet of the gas turbine is configuredto receive about 28,000 CFM of combustion air. The trailer may furtherinclude a plenum in fluid communication with the pair of ventilation airinlets, and the electrical generator may include one or more fans influid communication with the plenum and configured to draw the portionof ventilation air into an inlet of the electrical generator. Aremaining portion of ventilation air in the plenum may be configured tobe diverted to surround an outside of the electrical generator. Theportion of ventilation air may include about a ⅔ of the ventilation air,and the remaining portion of ventilation air may include about ⅓ of theventilation air. The ventilation air in the plenum may include around15,000 CFM, the inlet of the electrical generator may be configured toreceive about 10,000 CFM of ventilation air, and the remaining portionof ventilation air to surround the outside of the electrical generatormay include about 5,000 CFM.

The electrical generator may be configured to release the portion ofventilation from within through an outlet of the electrical generatorfor combination with the remaining portion of ventilation airsurrounding the electrical generator to form a recombined ventilationair. A base opening section may be configured to receive the recombinedventilation air and direct the recombined ventilation air in adownstream flow for capture an air capture area that may include a fanunit. The fan unit may be configured to release the recombinedventilation air to atmosphere. The air capture area may be configured tosurround a diffuser disposed downstream of the gas turbine toward thefront end of the trailer.

A plurality of silencer hoods respectively may include a plurality ofair inlets, each air inlet of each silencer hood disposed at a top endof each silencer hood and in fluid communication with a correspondingair inlet of the plurality of air inlets disposed on the side panel ofthe trailer. One or more vane depositors may be positioned in eachsilencer hood between each air inlet disposed at the top end of eachsilencer hood and the corresponding air inlet disposed on the side panelof the trailer, wherein each vane depositor is configured to extractwater from air

In another embodiment, method for air filtration in a mobile powergeneration system may include providing the mobile power generationsystem including a trailer including a rear end, a front end, a bottomend, and a top end defining therebetween an interior space, a gasturbine housed inside the trailer in the interior space, an electricalgenerator coupled to the gas turbine to generate electricity and housedinside the trailer in the interior space, the electrical generatorcomprising an inlet and one or more fans in fluid communication with theinlet, and at least a pair of ventilation air inlets and a plurality ofcombustion air inlets disposed near the top end of the trailer on a sidepanel of the trailer, the side panel disposed below the top end andbetween the rear end and the front end of the trailer. The method mayfurther include receiving, into the gas turbine, combustion air from theplurality of combustion air inlets for combustion in the gas turbine,receiving, into and around the electrical generator, ventilation airfrom the pair of ventilation air inlets, cooling the electricalgenerator through the ventilation air, releasing the ventilation airfrom the electrical generator, and releasing the ventilation air toatmosphere.

In embodiments, receiving, into the gas turbine, combustion air from theplurality of combustion air inlets comprises may include receivingcombustion air through the plurality of combustion air inlets, drawingthe combustion air to a first plenum centrally and fluidly disposedbetween the plurality of combustion air inlets, and directing thecombustion air from the first plenum into the gas turbine. Receiving,into and around the electrical generator, ventilation air from the pairof ventilation air inlets may include receiving ventilation air throughthe pair of ventilation air inlets, drawing the ventilation air into asecond plenum in fluid communication with the pair of ventilation airinlets, drawing a first portion of the ventilation air from the secondplenum into the inlet of the electrical generator through the one ormore fans of the electrical generator, and drawing a second portion ofthe ventilation air from the second plenum to around an outside of theelectrical generator.

These and additional features provided by the embodiments describedherein will be more fully understood in view of the following detaileddescription, in conjunction with the drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following detailed description of the present disclosure can be bestunderstood when read in conjunction with the following drawings, wherelike structure is indicated with like reference numerals and in which:

FIG. 1 illustrates a passenger side elevation view of an example mobilepower generation system on a mobile unit such as a trailer, which isattached to a tractor, according to one or more embodiments of thepresent disclosure;

FIG. 2 illustrates another passenger side elevation view of the mobileunit of FIG. 1 in addition to a noise attenuation assembly, according toone or more embodiments of the present disclosure;

FIG. 3 illustrates a driver side elevation view of the mobile unit ofFIG. 2;

FIG. 4 illustrates a top plan cross-sectional view of the mobile unit ofFIG. 2;

FIG. 5 illustrates an isometric view of an exhaust elbow of the mobileunit of FIG. 2 including a plurality of baffles, according to one ormore embodiments of the present disclosure;

FIG. 6 illustrates a side elevation view of the exhaust elbow of FIG. 5;

FIG. 7 schematically illustrates a top plan view of a fixture assemblyincluding a fixture and a plurality of pads, the fixture assemblyconfigured to arrange pads to support an electrical generator in aportion of the mobile unit of FIG. 2, according to one or moreembodiments of the present disclosure;

FIG. 8A schematically illustrates a top plan view of the fixture of FIG.7;

FIG. 8B schematically illustrates a side elevation view of the fixtureof FIG. 8A;

FIG. 9A schematically illustrates a top plan view of an examplegenerator pad of the fixture assembly of FIG. 7;

FIG. 9B schematically illustrates a side elevation view of the examplegenerator pad of FIG. 9A;

FIG. 10A schematically illustrates a top plan view of an example soleplate of the fixture assembly of FIG. 7;

FIG. 10B schematically illustrates a side elevation view of the examplesole plate of FIG. 10A; and

FIG. 11 schematically illustrates a closed cell base structure supportedby one or more support jacks, according to one or more embodiments ofthe present disclosure;

FIG. 12 schematically illustrates a side elevation view of an opticalalignment system for online leveling of a rotor of the electricalgenerator with the gas turbine based on positioning of the one or moresupport jacks, according to one or more embodiments of the presentdisclosure;

FIG. 13 schematically illustrates an electrical generator including oneor more taps to provide power to generator parasitic loads such as theone or more auxiliary systems while also providing the main primary loadoutput power through line ends, according to one or more embodiments ofthe present disclosure; and

FIG. 14 schematically illustrates a system for implementing a computerand software-based method to operate one or more systems describedherein, such as an optical alignment system, according to one or moreembodiments of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially to FIG. 1, a mobile power generation system 100described herein includes a mobile unit 102 that may include a trailer104 coupled to a tractor 106, each of the trailer 104 and tractor 106including a plurality of wheels 108. The trailer 104 includes a rear end110, a front end 112 to which the tractor 106 is configured to beattached, and side panels 114 disposed between the rear end 110 andfront end 112. The side panels 114 each comprises one or more accessdoors 116 configured to access areas of the mobile power generationsystem 100 housed inside the trailer 104. The trailer 104 furtherincludes a top end 118 and a bottom end 119 respective disposed alongtop and bottom portions of the side panels 114 and connecting the frontend 112 to the rear end 110.

A power control room 244 including, among other components, switchgear,may be positioned at the rear end 110 of the trailer 104 and may bemaintained as a regulated portion R at a desired room temperaturethrough an integrated heat, ventilation, and air conditioning (HVAC)system 260, which is described in greater detail below. The rear end 110of the trailer 104 may further include one or more wall sockets toreceive respective coupling cables through which electrical power may besent to one or more of the surface pumping systems to couple to andoperate the fluid pumps.

By way of example and not as a limitation, the trailer 104 houses a gasturbine 120 and an electrical generator 122 coupled to and placed incooperation with the gas turbine 120. The gas turbine 120 is acombustion engine that may further include a transmission shaft thatextends from its main rotational shaft(s) (i.e., coupled to the engine'scompressor or turbine) to deliver power to the electrical generator 122.The electrical generator 122 may be placed in cooperation with a driveshaft of the gas turbine 120 so that mechanical power from the gasturbine 120 is converted to electric power for use by one or moreelectric motors (not shown). Each electric motor may be part of one ormore surface pumping systems at a fracturing operation site.

The gas turbine 120 is a combustion engine configured to convert fuelssuch as natural gas into mechanical energy that drives the electricalgenerator 122 to produce electrical energy. The gas turbine 120 may be,for example, an aeroderivative ROLLS-ROYCE 501-K series industrial gasturbine as distributed by OnPower, Inc. of Lebanon, Ohio. The gasturbine 120 may include integrated reduction gear including gearing forreduction of a turbine speed to an alternator speed for the electricalgenerator 122. By way of example and not as a limitation, the turbinespeed may be in a range of from about 14,500 RPM to about 14,600 RPM at,respectively, a range of from about 50 Hz to about 60 Hz. Further, thereduced alternator speed may be in a range of from about 1,500 RPM toabout 1,800 RPM at, respectively, a range of from about 50 Hz to about60 Hz. A start system including a starter source as known to thoseskilled in the art may be used to start the gas turbine 120.

The gas turbine 120 is configured to compress combustion air in acompressor and mix the compressed air with fuel that is burned at hightemperatures to combust and to produce a pressurized, heated gas. Forexample, combustion air as described herein refers to incoming air thatis directed toward the gas turbine 120 for combustion. The pressurized,heated gas moves through turbine blades downstream of the compressor inthe gas turbine 120 to cause the turbine blades to spin. Thepressurized, heated gas may be heated to about 1895 degrees Fahrenheitfor example. The spinning turbine blades turn a drive shaft of the gasturbine 120, which drive shaft is connected to a rotor of the electricalgenerator 122. The rotor is configured to turn a magnetic device that issurrounded by wire coils in the electrical generator 122 to causecreation of a magnetic field that leads to movement of electrical chargethrough the wire in the production of electricity. The electricalgenerator 122 described herein is coupled to the gas turbine 120 togenerate electricity, and both the electrical generator 122 and the gasturbine 120 are housed inside the trailer 104 in an interior space Idefined by and within the rear end 110, the front end 112, the top end118, the bottom end 119, and the pair of side panels 114 of the trailer104. For example, the electrical generator 122 is coupled to the gasturbine 120 through reduction gearing 123, which all having rotatingelements that interact together to product electricity.

Referring to FIGS. 2-3, a noise attenuation assembly 124 is configuredto be attached to the top end 118 of the trailer 104. The noiseattenuation assembly 124 is attached to and in fluid communication withto an exhaust silencer system 140, described in greater detail furtherbelow, which exhaust silencer system 140 is attached to the front end112 of the trailer 104 of the mobile unit 102.

The noise attenuation assembly 124 further comprises a plurality ofsilencer hoods respectively comprising at top ends one or morecombustion air inlets 126 or one or more ventilation air inlets 182,which are described in greater detail further below. The plurality ofsilencer hoods are disposed along outer edges of and extend upwardlywith respect to side walls of an exhaust silencer unit 170 of the noiseattenuation assembly 124, described in greater detail further below, andare further configured to attenuate noise as described herein. Aplurality of combustion air inlets 126 and a pair of ventilation airinlets 182 at tops of the silencer hoods, as shown in FIG. 2, attach toand are in fluid communication with respective, corresponding combustionair inlets and ventilation air inlets disposed below the top end 118 andon side panels 114 of the trailer 104, as shown in FIG. 1. As describedin greater detail below, ventilation air as described herein refers toincoming air that is drawn in by the ventilation air inlets 182 and usedfor ventilation and cooling of at least the electrical generator 122.Thus, each air inlet 126, 182 at each top end of each silencer hood isin fluid communication with a corresponding air inlet disposed on anupper portion of a side panel 114 of the trailer 104. As a non-limitingexample, one or more vane depositors, such as a 2 and half pass (i.e.,turn) vane depositor, configured to extract water from air may bepositioned between each inlet 126, 182 and a respective correspondingair inlet disposed on the upper portion of a side panel 114 of thetrailer 104.

By way of example and not as a limitation, the gas turbine 120 receivescombustion air from a pair of combustion air inlets 126 mounted alongtop, side portions of the trailer 104 of the mobile unit 102. Eachcombustion air inlet 126 may include an opening sized and shaped to holdan air filter 128. In embodiments, as illustrated in FIG. 4, a pair ofair filters 128′ may be doubled up such that one air filter 128 isstacked within another air filter 128. The pair of air filters 128′ maybe received in the opening of a respective combustion air inlet 126,which may be a 2 foot by 2 foot opening, for enhanced silencing andfiltration. A plurality of baffles 130 may be positioned between thecombustion air inlets 126 to assist with absorption of noise energy andmay be, for example, about 2 inches to about 8 inches thick each.

Combustion air from each combustion air inlet 126 may be drawn toward acentral meeting point in a plenum 132 in cooperation with the combustionair inlets 126 and down through a duct 134 disposed between the plenum132 and the gas turbine 120 for receipt in the gas turbine 120. The duct134 may be a bell-mouth inlet duct configured to be a convergent inletair duct to direct combustion air into an inlet of the gas turbine 120.The bell-mouth inlet duct area may get smaller as combustion air flowsinto the gas turbine 120. As a non-limiting example, about 28,000 CFM ofcombustion air may be received by the gas turbine 120.

Referring to FIGS. 2-6, the mobile power generation system 100 includesthe exhaust silencer system 140 disposed at the front end 112 of thetrailer 104 of the mobile unit 102. The exhaust silencer system 140includes a diffuser system 142 coupled to a lower exhaust elbow silencer144 that is coupled to and in fluid communication with an upper exhaustelbow 146. The upper exhaust elbow 146 is configured to be coupled toand in fluid communication with the noise attenuation assembly 124 suchthat gas exiting from the exhaust silencer system 140 is receivedthrough at least an inlet of the noise attenuation assembly 124 andflows in a direction from the front end 112 to the rear end 110 of thetrailer 104, as described in greater detail further below.

Exhaust gas from a downstream end of the gas turbine 120 flows through adiffuser 148 of the diffuser system 142. The diffuser 148 is configuredto reduce the speed and decrease the pressure of the exhaust gas whiledirecting the exhaust gas into a collector 150 of the diffuser system142. The diffuser 148 is coupled to the gas turbine 120, and thecollector 150 is coupled to and in fluid communication with the lowerexhaust elbow silencer 144 of the exhaust silencer system 140. As anon-limiting example, a diameter of the diffuser 148 is increased from20 inches to about 30 inches to decrease pressure.

The lower exhaust elbow silencer 144 is attached to the diffuser 148 andthe collector 150. The exhaust gas flows from the collector 150 into abottom end 152 of the lower exhaust elbow silencer 144 of the exhaustsilencer system 140 and then turns at an upward angle from the bottomend 152 into a side portion 154 of the lower exhaust elbow silencer 144of the exhaust silencer system 140. The lower exhaust elbow silencer 144includes the bottom end 152 configured to receive gas from the diffusersystem 142, and the side portion 154 angled upwardly with respect to thebottom end 152. The exhaust gas flows through the side portion 154 to atop end 156 of the lower exhaust elbow silencer 144. The top end 156defines an outlet, the outlet including a plurality of spacings definedby and between a plurality of baffles 160 configured to attenuate noiseand described below. At the top end 156, the exhaust gas flows into theupper exhaust elbow 146 and turns again at a sideways angle to flowthrough into the noise attenuation assembly 124. For example, the upperexhaust elbow 146 includes an upper portion that is longitudinallyattached to the noise attenuation assembly 124 and is angled withrespect to the lower exhaust elbow silencer 144. The angles of turndescribed herein may each be, for example, a 90 degree angle. The lowerexhaust elbow silencer 144 and the upper exhaust elbow 146 may incombination form a U-shaped elbow structure.

With respect to the lower exhaust elbow silencer 144, a vertical space158 is defined between the bottom end 152 and the top end 156 along awidth defined by internal walls of the side portion 154. The pluralityof baffles 160 may be disposed in the vertical space 158. The pluralityof baffles 160 are configured to assist with noise attenuation throughsilencing of the exhaust gas. The plurality of baffles 160 may bedistributed in a parallel arrangement in the vertical space 158 of thelower exhaust elbow silencer 144. The plurality of baffles 160 may havea thickness in a thickness range of from about six (6) inches to abouteight (8) inches thick, respectively. The plurality of baffles 160 maybe distributed in a vertical, parallel fashion in the vertical space 158as illustrated in FIGS. 5-6.

The plurality of baffles 160 may have closed top ends 162 definingspacing 164 between a pair of baffles 160. The plurality of baffles 160may include bottom ends 166 curving toward the direction of exhaust airintake in a pointed configuration. The bottom ends 166 may be closed.Each baffle 160 may be made of stainless steel, fiberglass, likematerials, or a combination thereof to assist with absorption of noiseenergy.

The top end 156 of the lower exhaust elbow silencer 144 is in fluidcommunication with a bottom end of the upper exhaust elbow 146. Theupper exhaust elbow 146 has a top end that is in fluid communicationwith a top-mounted, exhaust silencer unit 170 of the noise attenuationassembly 124. The exhaust gas flows through the exhaust silencer unit170 for release to atmosphere through a turbine exhaust opening 172.

The exhaust silencer unit 170 may include a pair of coupled silencercomponents 174 that are in fluid communication with one another andmounted to the top end 118 of the trailer 104 of the mobile unit 102.Each silencer component 174 may extend with a length of twenty (20) feetand have a width of eight (8) feet and a height of four (4) feet, suchthat the exhaust silencer unit 170 with a pair of coupled silencercomponents 174 is forty (40) feet long, eight (8) feet wide, and four(4) feet tall.

Further, each silencer component 174 may include a central openingextending between ends of the silencer component 174. Each silencercomponent 174 may also include a first frame portion of materialsurrounding the central opening and made of, for example, a perforatedstainless steel such as 304 stainless steel. Each silencer component 174may include a second frame portion that may surround the first frameportion. The second frame portion may be made of an acousticalinsulation material such as, for example, fiberglass or a like materialsuitable to absorb noise energy. For example, the acoustical insulationmaterial may be made of FIBERGLAS TIW Types I and/or II Insulations asavailable from OWENS CORNING comprising a thermal insulating wool thatis configured for use in applications up to 1000 degrees Fahrenheit.Each silencer component 174 may include a third frame portion that maysurround the second frame portion and may be made of outer enclosurematerial such as steel or a like metal material. A plurality of metalstuds may connect one or more of the frame portions to one another.

In embodiments, referring to FIGS. 2-4, a ventilation system 180configured to provide electrical generator cooling may include a pair ofventilation air inlets 182 in fluid communication with a plenum 184,which is in fluid communication with an inlet of the electricalgenerator 122 comprises one or more fans such that a portion of air isdrawn into the inlet of the electrical generator 122 and excess air isdirected around the electrical generator 122. Atmospheric air is drawnin as ventilation air through an axial fan disposed in an openingdefining each ventilation air inlet 182. Walls defining the opening toreceive the axial fan may define a 2 foot by 2 foot space. An air filter128 disposed in each opening of each ventilation air inlet 182 assiststo clean the ventilation as well.

In embodiments, approximately ⅔ of the ventilation air is drawn throughthe plenum 184 and through the inlet of the electrical generator 122 topass into the electrical generator 122. The other ⅓ of the ventilationair is drawn through the plenum 184 and is diverted around an outsidewall of the electrical generator 122. As an example and not as alimitation, approximately 15,000 CFM of ventilation air may be drawn inthrough the ventilation air inlets 182 and drawn through the plenum 184such that (1) about 10,000 CFM is drawn into the electrical generator122 through the inlet for generator cooling and (2) about 5,000 CFM isdiverted to surround the outside of the electrical generator 122.

Ventilation air from within the electrical generator 122 is releasedthrough an outlet and combines with the ventilation air surrounding theelectrical generator 122 to travel through a base opening section 186downstream toward the front end 112 of the trailer 104 and below adownstream end of the gas turbine 120 for capture at an air capture area188 surrounding the diffuser 148. The air may then be released toatmosphere through a fan unit 190 disposed at the air capture area 188.

An air-oil heat exchanger 192 including an oil cooler system 194 mayalso be positioned in the air capture area 188. The oil cooler system194 may include an oil cooler, a top ventilation air and oil cooler airoutlet, and a pair of hoods defining cooler inlets, each hoodrespectively disposed on and extending outwardly from side panels 114 ofthe trailer 104 of the mobile unit 102 near the front end 112. The topventilation air and oil cooler air outlet may be disposed on a portionof the top end 118 of the trailer 104 positioned above the air capturearea 188. Oil from the gas turbine and oil from the reduction gear maybe able to flow through paths fluidly coupled to the oil cooler system194 for cooling. The fan unit 190 may be used for cooling both theelectrical generator 122, a gearbox for the reduction gearing, the gasturbine 120, and the air-oil heat exchanger 192. The air-oil heatexchanger 192 may be part of a lubrication oil system as known to thoseskilled in the art for lubrication of the gas turbine 120, the gearbox,and the electrical generator 122.

The mobile power generation system 100 may include a compressor hot airsupply system 200 for the anti-icing of filtration systems, such as forthe anti-icing of the inlet of the gas turbine 120 along the bell-mouthduct 134. For example, icing on the air filters 128 of the filtrationsystem may raise a pressure drop of the mobile power generation system100 and diminish the power output to lead to gas turbine shut down.Thus, gas turbine efficiency and power output drops as the pressure dropincreases due to icing on the air filters 128. Further, icing in thecompressor may lead to damage to the internal components of the gasturbine 120. Raising an inlet air temperature may assist to diminish arisk of ice formation in the bell mouth duct at the inlet of the gasturbine 120. The compressor hot air supply system 200 may be configuredto take hot air from the gas turbine compressor bleed. For example, hotair may be sent through pipes from the compressor of the gas turbine 120to bleed into a reservoir and to, from the reservoir, be distributedthrough an anti-icing nozzle in an opposite direction of the air flow.

The mobile power generation system 102 includes wheels 108 of the mobileunit 102, which wheels 108 may include frame portions made out of ametal material, such as steel, aluminum, or the like. One or moresupport jacks 202 may be used to support and align the trailer 104 ofthe mobile unit 102 with respect to a ground 203.

Referring to FIGS. 1-3 and 11, one or more of the support jacks 202 maysupport a base 204 of the trailer 104 disposed along the bottom end 119of the trailer 104. The base 204 may include a closed cell basestructure 205 comprising a rigid surface configured to be mounted on topof the support jacks 202. When mounted on top of the support jacks 202,the closed cell base structure 205 is further configured to providetorsional stability to assist with distribution of uneven loads due tovariance of forces from the support jacks 202. For example, FIG. 11illustrates a shear flow within the closed cell base structure 205 thatprovides the closed cell base structure 205 with a sufficient amount oftorsional stiffness required due to possible deflections at each trailersupport point as supported by the support jacks 202.

The closed cell base structure 205 includes a U-shaped design with anexterior base 206 comprising the rigid surface configured to be mountedon the support jacks 202, intermediate exterior side walls 208 extendingupwardly from side ends of the exterior base 206, and end exterior sidewalls 210 extending upwardly from outer ends of the exterior base 206.Top portions of the end exterior side walls 210 project inwardly to formthick end wall portions 211 each defining a wall thickness. A topopening 212 is defined by the thick end walls portions 211, top surfaces209 of the intermediate exterior side walls 208, and interior base walls214 extending therebetween to form the U-shaped design.

The thick end wall portions 211 of the end exterior side walls 210 areconfigured for a closed cell design (as indicated by the dashed lines inFIG. 11) to promote rigidity of the closed cell base structure such thateccentric load is distributed as shear forces across the closed cellbase structure rather than as a punch load between a support jack 202and the base 204. The closed cell base structure 205 thus is configuredto provide a rigid design to promote stiffness and minimize bending withrespect to the base 204 of the trailer 104 when supported on the one ormore support jacks 202. In embodiments, the closed cell base structure205 may be made of carbon and alloy steel, such as an ASTM A572-50plate. The plate may include a wall thickness in a range of from about ¼feet to about ⅜ feet, and the closed cell based structure 205 may beabout 24 inches in height and 97 inches in length, though other suitabledimensions as understood to those skilled in the art are with the scopeof this disclosure.

Referring to FIG. 12, the mobile power generation system 100 may includean optical alignment system 220 for online leveling with respect tosupport jacks 202, trailer 104, and the ground 203. The opticalalignment system 220 may be configured to send an alert upon a desiredleveling of the trailer 104 with respect to ground by the support jacks202 and/or to send an alert upon a leveling occurring outside of adesired range angle. The optical alignment system 220 is configured toalign the gas turbine 120 with a rotor of the electrical generator 122at a desired alignment, such as one shown in FIG. 1.

The optical alignment system 220 may include a camera kit including acamera 222. The camera kit may be a 8400 series camera kit availablefrom the Brunson Instrument Company. The camera 222 may be mounted onthe gas turbine 120 with a field of view (FOV) directed toward theelectrical generator 122. One or more targets 224 for the camera 222 maybe positioned on respective one or more generator pads 230, which aredescribed in greater detail below, supporting the electrical generator122.

Once a camera laser 226 transmitted from the camera 222, for example, isaligned with the one or more targets 224, a desired alignment isachieved. The optical alignment system 220 may be configured to send analert or other notification once the desired alignment is achieved toindicate onsite leveling. The one or more support jacks 202 may beadjusted in height until the desired alignment is achieved. A digitalvideo feed from the camera 222 may be sent back to a controller forviewing on a display of a computing device to provider a user with avisual depiction of the alignment or misalignment between the gasturbine 120 and the electrical generator 122 as well.

For example, and referring to FIG. 14, a system 300 for implementing acomputer and software-based method to, for example, operate the opticalalignment system 220 described herein may be implemented using agraphical user interface (GUI) provided such a display that isaccessible at a user workstation 302 (e.g., a computer), an applicationserver 304, a database 306, a computer-readable memory 308, a processor310, and a network 312 connected through communication lines 314. Thesystem 300 can include multiple workstations 302 and application servers304 containing one or more applications that can be located atgeographically diverse locations. In some embodiments, the system 300 isimplemented using a wide area network (WAN), such as an intranet or theInternet. The workstation 302 may include digital systems and otherdevices permitting connection to and navigation of the network 312through which components of the system are connected through wired orwireless communication lines 314 that indicate communication rather thanphysical connections between the various components.

The computer-readable memory 308 may be configured as computer readablemedium that is non-transitory in that computer-readable memory 308 isnot a transitory signal but is a storage medium that may storenonvolatile and volatile signals and, as such, may include random accessmemory (including SRAM, DRAM, and/or other types of random accessmemory), flash memory, registers, compact discs (CD), digital versatilediscs (DVD), magnetic disks, and/or other types of storage components.Additionally, the computer-readable memory 308 may be configured tostore, among other things, computer readable instructions, and any datanecessary to aid the optical alignment system 220 described below.

As stated above, the processor 310 may include any processing componentconfigured to receive and execute instructions (such as from thecomputer-readable memory 308). It is noted that the processor 310 aswell as any additional controller hardware may be programmed to executesoftware instructions stored on the computer-readable memory 308. Insome embodiments, the additional controller hardware may comprise logicgates to perform the software instructions as a hardware implementation.The processor 310 may be configured as, but not limited to, ageneral-purpose microcontroller, an application-specific integratedcircuit, or a programmable logic controller.

The optical alignment system 220 may include one or more sensors thatmay be incorporated into larger systems, and may be able to communicatewith external devices and components of such systems via input/outputhardware (not shown). The input/output hardware may include any hardwareand/or software for sending and receiving data to an external device.Exemplary input/output hardware includes, but is not limited to,universal serial bus (USB), FireWire, Thunderbolt, local area network(LAN) port, wireless fidelity (Wi-Fi) card, WiMax card, and/or otherhardware for communicating with other networks and/or external devices.

Referring to FIGS. 1-3, the mobile unit 102 may include one or moreauxiliary systems to support operating equipment such as fuel supplypiping, the start system, the lubrication oil system 240 including alubrication oil tank and drain, a fire detection and extinguishingsystem 242, and the power control room 244. The fire detection andextinguishing system 242 may include a light-weight FM-200 firesuppression system as available from DUPONT.

Referring to FIGS. 1-2, one or more pressurized bottles 246 includingFM-200 may be stored on a single side of the trailer 104 in an interiorarea near an end of the electrical generator 122 positioned toward thepower control room 244 and away and upstream from the gas turbine 120.For example, two pressurized bottles 246 may be stored behind the sidepanel 114 on a passenger side of the trailer 104 near the electricalgenerator 122 and may be accessible by a side access door 116A of thetrailer 104 positioned to provide access to the fire detection andextinguishing system 242. Other fire suppression systems known to thethose skilled in the art, such as those utilizing carbon dioxide, whichis heavier that FM-200, are within the scope of this disclosure as well.

Referring to FIG. 13, electrical generator 122 may include one or moretaps 250 to provide power to generator parasitic loads such as the oneor more auxiliary systems while also providing the main primary loadoutput power. For example, the electrical generator 122 may beconfigured to provide a 2600V-alternating current (AC) primary load (upto around 5,000 kW). The generator parasitic loads may require around480V-AC (up to around 45 kW).

The electrical generator 122 may be configured to include a three-phrasevoltage circuitry 251 including sets of three conductors and phasecoiling such that a line-to-line voltage between ends of any of thethree lines L1, L2, L3 generates the primary load (i.e., 2600V-AC).Further, at select points of each line, a tap 250 may be positioned todraw an auxiliary voltage of around 480V-AC from the line-to-lineconfiguration. Thus, each tap 250 on each line may act as anauto-transformer and have a line-to-line voltage with another tap 250 onanother line of the parasitic load (i.e., 480V-AC). Use of such taps 250on the electrical generator 122 eliminates a need for an additionalsingle-phase transformer as an additional, weighted component to drawnauxiliary power thus reducing weight, components, and potentiallycomplexity and cost of the system. Each tap 250 may be, for example, aseparate low voltage winding tab configured to draw auxiliary power fromthe electrical generator 122 based on the position of the tap 250 withrespect to the three-phase conductors of the electrical generator 122.

In embodiments, and referring back to FIG. 1, the trailer 104 of themobile unit 102 may include a series of side access doors 116 on eachside panel 114 to access various components and systems in the trailer104. For example, another side access door 116B may be positionedadjacent to the power control room 244 to permit access to the powercontrol room 244.

The power control room 244 may include, for example, a switchgearcenter, a motor control center, a unit control panel, a fire systempanel communicatively coupled to the fire detection and extinguishingsystem 242, an instrument air supply compressor, one or more electronicstorage devices such as a battery and/or a charger, and one or moreelectrical connectors to supply power. One or more blowout panels B maybe positioned along a top portion of the rear end 110 of the trailer104. The blowout panels B may be configured to monitor pressure withinthe power control room 244 to open upon a pressure threshold beingreached such that pressure is released from the power control room 244to atmosphere. As a non-limiting example, the pressure threshold may bein a range of from about 1.5 to 3 times atmospheric pressure. Theblowout panels B are configured to mitigate damage from an electricalfailure of gear in the switchgear center. For example, the one or moreblowout panels B may include a pair of magnetic hinged doors disposed atan aft wall of the power control room 144 and configured to relievepressure in the power control room 244 as an arc flash protectionmechanism, which arc flash event causes rapid heating of gear in thepower control room 244.

The mobile power generation system 100 may further include an integratedheat, ventilation, and air conditioning (HVAC) system 260 that may bepositioned at the switchgear center at the rear end 110 of the trailer104. In embodiments, the blowout panel(s) B may be positioned above theHVAC system 260. The HVAC system 260 may include a plurality of ductwork and plenum systems throughout the mobile power generation system100 to supply and return air through a plurality of ducts and plenums,which may be made of metal and/or fiberglass, for example, for eitherheating or cooling of the mobile power generation system 100 in additionto the other sub-systems described herein. For example, the HVAC system260 may aid to maintain one or more rooms at a desired room temperature,such as the power control room 244 including switchgear at the rear end110 of the trailer 104, which is described in greater detail below. Inembodiments, the HVAC system 260 may keep the temperature in the powercontrol room 244 within a range of from about 50 degrees Fahrenheit toabout 150 degrees Fahrenheit.

In embodiments, and referring to FIGS. 7-10B, the electrical generator122 may be seated on a generator pad assembly 270 disposed on aninternal base 272 (i.e., floor) of the trailer 104 of the mobile unit102. The generator pad assembly 270 may include a plurality of generatorpads 230 fixed to the internal base 272, a respective plurality of soleplates 274 positioned above the generator pads 230 at a spacing, and asupportive material C positioned around the generator pads 230 and thesole plates 274 to fix them in an aligned position. For example, thesupportive material C may be a cured porous resinous material forchocking industrial machinery or equipment such as a CHOCKFAST ORANGE(PR-610TCF) compound as available by Illinois Tool Works (ITW)Engineered Polymers North America of Montgomeryville, Pa. A fixture 276may be used to position the generator pad assembly 270 in the alignedpositioned.

A method of assembling the generator pad assembly may include providingthe fixture 276 to use to fix the generator pad assembly 270 to theinternal base 272 of the trailer 104 of the mobile unit 102. Referringto FIG. 8A, the fixture 276 may include a plurality of base beams 278aligned and configured to form a desired alignment shape. For example,the fixture may include four base beams 278 forming a rectangle.

A plurality of mounting pads 280 may extend from at least two opposingbase beams 278. In an embodiment, a first pair of mounting pads 280′ arepositioned to extend from near ends of a first base beam 278′, and asecond positioned pair of mounting pads 280″ are positioned to extendfrom near ends of a second base beam 278″ that is placed opposite and inparallel to the first base beam 278′.

The plurality of mounting pads 280 are configured and sized and shapedto be seated within and atop a respective plurality of generator pads230 (FIGS. 9A-9B) when the fixture 276 is used to position the pluralityof generator pads 230 to the internal base 272. The plurality ofmounting pads 280 are further configured and sized and shaped to beseated atop a respective plurality of sole plates 274 (FIGS. 10A-10B)when the fixture 276 is used to position then plurality of sole plates274 to the internal base 272.

The plurality of generator pads 230 (FIGS. 9A-9B) are mounted onto theplurality of mounting pads 280 of the fixture 276 (FIGS. 8A-8B). Anupper facing surface of the fixture 276 faces upwardly, while a lowerfacing surface of the fixture 276 faces toward the generator pads 230and the internal base 272. The plurality of generator pads 230 arerespectively mounted onto a lower facing surface 290 of the plurality ofmounting pads 280 (FIG. 8B) of the fixture 276 such that a surroundingupwardly positioned dam portion 282 of each generator pad 230 surroundsand extends upwardly past ends of each mounting pad 280. Each mountingpad 280 is fixed to each generator pad 230 through connecting mechanismssuch as bolts through one or more apertures 284 in each mounting pad 280that may join with one or more apertures 286 in a respective generatorpad 230.

A center of a section of the internal base 272 may be established suchas by, for example, use of a string line for alignment and use of endweight markers to mark designed alignment points along the string line.One or more datum reference points may be established between thefixture and the internal base to set the fixture in a desired alignmentposition such that, for example, a center of the fixture 276 aligns withthe center of the section of the internal base 272 in which to seat theelectrical generator 122. The plurality of generator pads 230 may beseated against the internal base 272 in the desired alignment positionand then welded to the internal base 272. The fixture 276 may be removedfrom the plurality of generator pads 230 prior to or after the pluralityof generator pads 230 are welded to the internal base 272 of the trailer104 of the mobile unit 102 in the desired alignment position.

Once the plurality of generator pads 230 are established in anx-position and y-position with respect to the internal base 272, and thefixture 276 removed, the fixture 276 may be attached to the plurality ofsole plates 274 (FIGS. 10-10B) that will need to be established in afloating z-position with respect to respective generator pads 230. Forexample, the plurality of mounting pads 280 of the fixture 276 areconfigured to be seated against and attached to the plurality of soleplates 274. The lower facing surface 290 of each mounting pad 280 (FIG.8B) will attach to an upper facing portion 288 of each sole plate 274,and at least one bolt may be run through apertures 292 of each soleplate 274 and respective apertures 284 of each mounting pad 280 toattach the respective mounting pads 280 and sole plates 274 together.

A bolt may be positioned between each sole plate 274 and each respectivegenerator pad 230 above which each sole plate 274 is positioned at adesired z-position elevation. For example, each sole plate 274 may bevertically spaced from a respective generator pad 230 at a distance thatmay range from about ¼ inches to about ½ inches.

Once the plurality of generator pads 230, the plurality of sole plates274, and the fixture 276 is in place in the desired three-dimensionalpositions, a chocking compound may be poured around the generator padassembly 270 to approximately, for example, a quarter of an inch above alower-facing surface 294 of each sole plate 274. The chocking compoundmay cured for a period of time, which may range from about 12 hours to afew days. After the chocking compound is cured for the period of time,the fixture 276 may be removed from the sole plates 274 such that thegenerator pad assembly 270 is in a set position configured to receivethe electrical generator 122 in a seated position. Further, anyremaining bolts and studs that remained in position during the curingmay be removed from the assembly as well.

While certain representative embodiments and details have been shown forpurposes of illustrating the disclosure, it will be apparent to thoseskilled in the art that various changes may be made without departingfrom the scope of the disclosure, which is defined in the appendedclaims.

What is claimed is:
 1. A mobile power generation system comprising: atrailer including a rear end, a front end, a bottom end, and a top enddefining therebetween an interior space; a gas turbine housed inside thetrailer in the interior space; an electrical generator coupled to thegas turbine to generate electricity and housed inside the trailer in theinterior space; and a plurality of air inlets disposed on a side panelof the trailer, the side panel disposed below the top end and betweenthe rear end and the front end of the trailer, the plurality of airinlets in fluid communication with the gas turbine and the electricalgenerator, and the plurality of air inlets configured to receive andfilter air comprising at least one of combustion air and ventilationair.
 2. The mobile power generation system of claim 1, wherein theplurality of air inlets comprises at least a pair of ventilation airinlets and a plurality of combustion air inlets.
 3. The mobile powergeneration system of claim 2, wherein the plurality of combustion airinlets comprises a first pair of combustion air inlets and a second pairof combustion air inlets.
 4. The mobile power generation system of claim2, wherein each of the plurality of air inlets is configured to includean opening sized and shaped to hold an air filter, and each combustionair inlet comprises an opening configured to receive a pair of airfilters such that one air filter is stacked within another air filter.5. The mobile power generation system of claim 4, wherein the opening ofeach combustion air inlet is a 2 foot by 2 foot opening.
 6. The mobilepower generation system of claim 4, wherein the plurality of combustionair inlets comprises at least a pair of combustion air inlets, and aplurality of baffles is positioned between the pair of combustion airinlets, each baffle configured to assist with absorption of noise energyand having a thickness in a range of from about 2 inches to about 8inches thick.
 7. The mobile power generation system of claim 2, whereinthe gas turbine is configured to receive combustion air from theplurality of combustion air inlets and the electrical generator isconfigured to receive a portion of ventilation air from the pair ofventilation air inlets.
 8. The mobile power generation system of claim7, wherein the trailer further comprises a plenum centrally disposedbetween and in fluid cooperation with the plurality of combustion airinlets, and the gas turbine comprises a duct downstream of the plenumand disposed between the plenum and the gas turbine, the plenum and theduct configured for receipt of combustion air.
 9. The mobile powergeneration system of claim 8, wherein the duct comprises a bell-mouthinlet duct configured to be a convergent inlet air duct to directcombustion air into an inlet of the gas turbine.
 10. The mobile powergeneration system of claim 9, wherein the bell-mouth inlet ductcomprises an area that decreases in size in a downstream direction inwhich combustion air flows into the gas turbine.
 11. The mobile powergeneration system of claim 9, wherein the inlet of the gas turbine isconfigured to receive about 28,000 CFM of combustion air.
 12. The mobilepower generation system of claim 7, wherein the trailer furthercomprises a plenum in fluid communication with the pair of ventilationair inlets, and the electrical generator comprises one or more fans influid communication with the plenum and configured to draw the portionof ventilation air into an inlet of the electrical generator.
 13. Themobile power generation system of claim 12, wherein a remaining portionof ventilation air in the plenum is configured to be diverted tosurround an outside of the electrical generator.
 14. The mobile powergeneration system of claim 13, wherein the portion of ventilation aircomprises about a ⅔ of the ventilation air, and the remaining portion ofventilation air comprises about ⅓ of the ventilation air.
 15. The mobilepower generation system of claim 13, wherein the ventilation air in theplenum comprises around 15,000 CFM, the inlet of the electricalgenerator is configured to receive about 10,000 CFM of ventilation air,and the remaining portion of ventilation air to surround the outside ofthe electrical generator comprises about 5,000 CFM.
 16. The mobile powergeneration system of claim 13, wherein: the electrical generator isconfigured to release the portion of ventilation from within through anoutlet of the electrical generator for combination with the remainingportion of ventilation air surrounding the electrical generator to forma recombined ventilation air; a base opening section is configured toreceive the recombined ventilation air and direct the recombinedventilation air in a downstream flow for capture an air capture areacomprising a fan unit; and the fan unit is configured to release therecombined ventilation air to atmosphere.
 17. The mobile powergeneration system of claim 16, wherein the air capture area isconfigured to surround a diffuser disposed downstream of the gas turbinetoward the front end of the trailer.
 18. The mobile power generationsystem of claim 1, further comprising: a plurality of silencer hoodsrespectively comprising a plurality of air inlets, each air inlet ofeach silencer hood disposed at a top end of each silencer hood and influid communication with a corresponding air inlet of the plurality ofair inlets disposed on the side panel of the trailer; and one or morevane depositors positioned in each silencer hood between each air inletdisposed at the top end of each silencer hood and the corresponding airinlet disposed on the side panel of the trailer, wherein each vanedepositor is configured to extract water from air.
 19. A method for airfiltration in a mobile power generation system, the method comprising:providing the mobile power generation system comprising: a trailerincluding a rear end, a front end, a bottom end, and a top end definingtherebetween an interior space; a gas turbine housed inside the trailerin the interior space; an electrical generator coupled to the gasturbine to generate electricity and housed inside the trailer in theinterior space, the electrical generator comprising an inlet and one ormore fans in fluid communication with the inlet; and at least a pair ofventilation air inlets and a plurality of combustion air inlets disposednear the top end of the trailer on a side panel of the trailer, the sidepanel disposed below the top end and between the rear end and the frontend of the trailer; and receiving, into the gas turbine, combustion airfrom the plurality of combustion air inlets for combustion in the gasturbine; receiving, into and around the electrical generator,ventilation air from the pair of ventilation air inlets; cooling theelectrical generator through the ventilation air; releasing theventilation air from the electrical generator; and releasing theventilation air to atmosphere.
 20. The method of claim 19, wherein:receiving, into the gas turbine, combustion air from the plurality ofcombustion air inlets comprises: receiving combustion air through theplurality of combustion air inlets; drawing the combustion air to afirst plenum centrally and fluidly disposed between the plurality ofcombustion air inlets; and directing the combustion air from the firstplenum into the gas turbine; and receiving, into and around theelectrical generator, ventilation air from the pair of ventilation airinlets comprises: receiving ventilation air through the pair ofventilation air inlets; drawing the ventilation air into a second plenumin fluid communication with the pair of ventilation air inlets; drawinga first portion of the ventilation air from the second plenum into theinlet of the electrical generator through the one or more fans of theelectrical generator; and drawing a second portion of the ventilationair from the second plenum to around an outside of the electricalgenerator.